Method for determining the position and positioning a covered sensor element of a sensor arrangement, as well as a sensor arrangement with a correspondingly positioned sensor element.

Abstract

Method for determining the position and positioning of a covered sensor element (2) of a sensor arrangement (1; 22; 23; 24) comprising: - the sensor element (2) which is covered by a lid (5), - a base body (4) that carries the sensor element (2), by the following steps: - Forming a sensor receptacle (3) for the sensor element (2) in the base body (4), - Specifying at least one reference surface (7, 9; 11, 13) and / or at least one reference point (16, 17; 21) on the base body (4), - Measuring the distance of the reference surface (7, 9; 11, 13) and / or the reference point (16, 17; 21) to a predetermined sensor location of the sensor element (2) in the sensor mount (3), - Mounting the sensor element (2) in the sensor holder (3), - Attaching the cover (5) to the sensor element (2), - Positioning the base body (4) relative to a support body (25) such that the at least one reference surface (7, 9; 11, 13) and / or the at least one reference point (16, 17; 21) has a predetermined position relative to the support body (25).

Description

[0001] The invention relates to a method for determining the position and positioning of a covered sensor element of a sensor arrangement. Furthermore, the invention relates to a sensor arrangement with a sensor element positioned according to this method.

[0002] Such sensor arrangements are used particularly in the automotive industry. Installation locations include, for example, a transmission or engine compartment of a motor vehicle. The sensor elements are installed in control units, for example, to determine speed, travel, or other measured variables. A lead frame, for example, is used as a contact element for electrically contacting the sensor element with external components. In a preferred embodiment, the lead frames are encased in a base body, which is achieved in the prior art using a two-stage injection molding process. For technical reasons, particularly for chip protection, base body designs are required in which the sensor elements are provided with covers, particularly chip protection covers. With covered sensor elements, the exact position or orientation of the sensors, for example for positioning during installation in a transmission, can no longer be detected tactilely or optically.Known methods for determining the sensor's position rely on electromagnetic positioning of a sensitive surface. This is complex and costly, and also requires additional calibration of the measuring system. Furthermore, it is known to measure sensor receptacles in the base body as part of a destructive test. The disadvantages of such a method are obvious.

[0003] DE 203 06 654 U1 discloses a crankshaft sensor comprising a sensor carrier, at the front end of which a sensor element is arranged, and a circuit carrier with at least one electrical component, wherein the sensor element is attached to the circuit carrier and electrically connected to the circuit. The sensor carrier has a receiving area in which the circuit carrier is received in a position along the sensor carrier. The sensor element is attached to a front, front end of the circuit carrier and protrudes therefrom, so that it is arranged on the front side of the sensor carrier.

[0004] EP 1 672 328 A2 discloses a magnetic field sensor, in particular a speed sensor, direction of rotation sensor, or position sensor for the drive train of a motor vehicle. The magnetic field sensor comprises a sensor arrangement with a sensor element that responds to a magnetic field and, if appropriate, a permanent magnet, the latter being encased in plastic together with the sensor arrangement and parts of the connecting conductor tracks. The conductor tracks are one-piece with a locking device for the permanent magnet, and the sensor arrangement is designed as a stamped grid. The stamped grid is formed as a three-dimensional structure that supports the sensor arrangement and, if appropriate, surrounds the permanent magnet like a holder. The holder and the connecting conductor tracks are first stamped out of a sheet metal as a grid-like development and then deformed into the holder.

[0005] It is therefore an object of the present invention to further develop a method for determining the position and positioning of a covered sensor element in such a way that exact position determination and positioning is ensured with less effort.

[0006] This object is achieved according to the invention by a method having the features specified in claim 1.

[0007] According to the invention, it has been discovered that the specification of reference positions, i.e. reference surfaces and / or reference points, offers the possibility of breaking down the actual measuring problem, namely determining the position of the sensor element in relation to the support body, into two partial measuring tasks, whereby a first partial measuring task, namely determining the position of the reference position in relation to the sensor element, can be carried out with the sensor cover removed and the second partial measuring task with the sensor cover in place. Neither complex electromagnetic position determination nor destructive testing are required. The method according to the invention takes advantage of the fact that the base body of the sensor arrangement still has accessible points or surfaces after the sensor element has been covered, so that reference points or reference surfaces that could be detected tactilely or optically can be specified there.The reference positions are preferably specified as close as possible to the sensor receptacle. The reference positions are preferably designed such that they are produced in the same tool mold half as the receptacle pockets of the sensor elements, thus providing a corresponding reference dimension, for example, from a reference measuring surface to a base of a sensor receptacle pocket and thus to the sensor element itself. Provided that the relative positioning of the sensor element in the sensor receptacle is known with sufficient precision, referencing can also be carried out when the sensor element has not yet been installed. The method according to the invention serves to detect the position of the at least one sensor element which, after installation within the sensor arrangement, can no longer be measured tactilely or optically because it is covered by the cover.The position of the sensor element can then be determined using at least one reference surface and / or at least one reference point, which are fixed relative to the sensor element. Even after installation, the position of the sensor element can be checked on the sensor assembly, which may be designed as a sensor dome, for example, on a complete control unit in which the sensor assembly is integrated, or even in a transmission.

[0008] The method according to claim 2 is tailored to the process of currently typically used sensor arrangements.

[0009] Reference position specifications according to claims 3 and 4 enable a correspondingly exact position determination and positioning of the sensor element relative to the support body.

[0010] An injection molding process according to claim 5 allows for cost-effective production of the sensor assembly. This applies in particular if, according to claim 6, the sensor receptacle is formed during overmolding.

[0011] The advantages of a sensor arrangement according to claims 7 or 8 correspond to those already explained above with reference to the method according to the invention. A Hall sensor allows for particularly efficient parameter determination. Embodiments of the invention are explained in more detail below with reference to the drawings. They show: Fig. 1 shows in perspective a section of a sensor arrangement for detecting operating parameters of a motor vehicle, said section comprising a sensor element; Fig. 2 in one to Fig. 1 similar representation a further embodiment of a sensor arrangement; Fig. 3 and Fig. 4 in one to Fig. 1 similar representation further designs of a sensor arrangement and Fig. 5 three such sensor arrangements on a common carrier.

[0012] Fig. Figure 1 shows a section of a sensor arrangement 1 in the region of a sensor element 2. The sensor element 2 is arranged in a sensor receptacle 3, which in turn is formed in a base body 4 of the sensor arrangement 1. The base body 4 is also referred to as a sensor dome. The sensor element 2 is surrounded by a Fig. 1 is covered by a cover 5, shown transparently, which serves to protect the sensor element 2, for example, from mechanical or electrostatic influences, as well as to protect against short circuits. The cover 5 is connected to the base body 4, in particular, it is snapped onto it. The base body 4 and the cover 5 are made of plastic.

[0013] Contact pins of the sensor element 2 (not shown in detail) are connected via an electrically conductive connecting body 6, which is Fig. 1 is visible in the area of ​​cutouts left free in the base body 4, electrically connected to the Fig. 1, the sensor element 2 is connected to an external control or output device via connection pins (not shown). The connecting body 6 represents an electrical contact element. The connecting body 6 is overmolded with the base body 4. Alternatively, the connecting body 6 can also be mounted and / or caulked to the base body 4. The connecting body 6 is made, in particular, of copper.

[0014] The sensor element 2 is designed as a Hall sensor. For correct operation of the sensor arrangement 1, it is necessary to know the exact position of the sensor element 2 in space. Since the sensor element 2 is covered by the cover 5 and is therefore not directly optically accessible, reference points or reference surfaces are defined to determine the position of the sensor element 2 of the sensor arrangement 1. Such reference points or reference surfaces are also referred to below as equivalent measuring surfaces. A first equivalent measuring surface 7 of the sensor arrangement 1 is defined by a side wall of a Fig. 1 vertically extending reinforcement strut 8 of the base body 4. Another substitute measuring surface 9 is defined by a side wall of another reinforcement strut 10 of the base body 4, which is in the Fig. 1 also runs vertically. The two equivalent measuring surfaces 7, 9 are in a fixed relationship to each other and form approximately a right angle to each other.

[0015] Using the substitute measuring surfaces 7, 9, the position of the covered sensor element 2 is determined as follows: First, the sensor element 2 is contacted with the still exposed connecting body 6. Then, the connecting body 6, together with the sensor element 2, is surrounded by the base body 4, whereby the sensor receptacle 3 for the sensor element 2 is simultaneously formed in the base body 4. When overmolding the connecting body 6, the sensor receptacle 3 can also be specified in a different way and the sensor element 2 can be subsequently mounted in the sensor receptacle 3. The distance between the substitute measuring surfaces 7, 9 and a specified sensor location in the sensor receptacle 3, which corresponds to a corresponding sensor location of the sensor element 2 with the sensor element 2 mounted, is now precisely measured. This takes place with the cover 5 still removed, so that optical measurement is particularly possible.The specified sensor location is, for example, a central point in the sensor holder 3. In principle, the distance to the specified sensor location can therefore also be measured before the sensor element 2 has yet to be installed. In this case, the sensor holder 3 must be designed in such a way that the exact position of the mounted sensor element 2 in the sensor holder 3 is known before the sensor element 2 is installed. After the distance of the replacement measuring surfaces 7, 9 to the specified sensor location has been measured and after the sensor element 2 has been installed in the sensor holder 3, the cover 5 is attached to the sensor element 2. The base body 4 is then positioned relative to a support body for the sensor arrangement 1 in such a way that the two replacement measuring surfaces 7, 9 assume specified positions relative to this support body.This position specification is carried out in such a way that when the equivalent measuring surfaces 7, 9 assume these specified positions, the sensor element 2 is also necessarily correctly positioned. Thus, the method not only determines the position of the sensor element 2, but also positions the sensor element 2 correctly.

[0016] Fig. 2 shows a further embodiment of a sensor arrangement 1. Components corresponding to those described above with reference to the Fig. 1 have already been explained, have the same reference numbers and will not be discussed in detail again.

[0017] In the Fig. 2, the sensor element 2 covered by the protective cover 5 is not visible.

[0018] The sensor arrangement 1 according to Fig. 2 differs from that according to Fig. 1 mainly by the positioning of the sensor element relative to the base body 4. A free end of the base body 4 of the sensor arrangement 1 carrying the sensor element 2 according to Fig. 2 is bent at an angle of approximately 30°, so that the sensor element 2 lies in a correspondingly inclined sensor plane. A first substitute measuring surface 11 is provided in the sensor arrangement 1 according to Fig. 2 by a viewer of the Fig. 2 facing side wall 12 of the base body 4. A further substitute measuring surface 13 is formed by an end wall 14 of the base body 4 of the sensor arrangement 1, which is inclined correspondingly to the inclination of the sensor plane. Fig. 2 specified.

[0019] A position determination and a positioning of the sensor element of the sensor arrangement 1 according to Fig. 2 shall be in accordance with what has been stated above with reference to the Fig. 1, with the difference that the replacement measuring surfaces 11 and 13 are now used.

[0020] Fig. 3 shows a further embodiment of a sensor arrangement 1. Components corresponding to those described above with reference to the Fig. 1 and Fig. 2 have already been explained, have the same reference numbers and will not be discussed in detail again.

[0021] The sensor arrangement 1 according to Fig. 3 differs from that according to Fig. 2 in the design of the base body 4 as well as in the angle of inclination of a sensor plane 15, which in the embodiment according to Fig. 3 is less inclined than in the execution according to Fig. 2.

[0022] When executing according to Fig. 3, reference points 16, 17 are specified, the function of which corresponds to that of the substitute measuring surfaces of the versions according to the Fig. 1 and Fig. 2. The reference point 16 is located at a predetermined circumferential position at a predetermined height on an outer wall 18 of the base body 4. The reference point 17 is located on a cover section 19, which is arranged near the sensor element and is an integral part of the base body 4. The reference point 17 is located in the sensor plane 15. Alternatively, it is possible to arrange the reference point 17 centrally on the surface of the cover 5.

[0023] When positioning the base body 4 in the version according to Fig. 3 relative to a support body, it is ensured that the two reference points 16, 17 each have a specified position relative to the support body. In preparation, the distance between the reference points 16, 17 and the specified sensor location is measured with the cover removed.

[0024] Fig. 4 shows a further embodiment of a sensor arrangement 1. Components corresponding to those described above with reference to the Fig. 1 to 3 have already been explained, have the same reference numbers and will not be discussed in detail again.

[0025] The sensor arrangement according to Fig. 4 differs from that according to Fig. 3 in turn by the shape of the base body 4 and by the angle of inclination of a sensor plane 20. The latter is in the embodiment according to Fig. 4 is inclined approximately as strongly relative to a longitudinal extension of the base body 4 as in the embodiment according to Fig. 2 is the case.

[0026] When executing according to Fig. 4 is placed next to the replacement measuring surface 13 (see also Fig. 2) another reference point 21 is specified, the position of which corresponds to that of the reference point 17 according to the Fig. 3 and which lies in the sensor plane 20.

[0027] When determining the position and positioning of the sensor element 2, the distance of the equivalent measuring surface 13 and the distance of the reference point 21 to the specified sensor location are measured, and then the base body 4 is positioned relative to a support body such that the equivalent measuring surface 13 and the reference point 21 each have a specified position relative to the support body. Otherwise, the position determination and positioning of the sensor element corresponds to the embodiment according to Fig. 4 what was stated above with reference to the statements made after the Fig. 1 to 3 were explained.

[0028] Fig. Figure 5 shows three further embodiments of sensor assemblies 22, 23, 24 mounted on a common support body 25. Components of the sensor assemblies 22 to 24 corresponding to those described above with reference to Fig. 1 to 4 have already been explained, have the same reference numbers and will not be discussed in detail again.

[0029] The Fig. 5 The sensor arrangement 22 shown on the left corresponds to the sensor arrangement 1 according to Fig. 1. At the end opposite the sensor receptacle 3, the base body 4 of the sensor assembly 22 has a base plate 26, which is screwed to the plate-shaped support body 25. The sensor assemblies 23 (see Fig. 5, middle) and 24 (compare Fig. 5, right). The sensor arrangement 23 corresponds to the sensor arrangement 1 according to Fig. 2. The sensor arrangement 24 corresponds to the sensor arrangement 1 according to Fig. 3.

Claims

[1] Method for determining the position and positioning of a covered sensor element (2) of a sensor arrangement (1; 22; 23; 24), comprising: - the sensor element (2), which is covered by a cover (5), - a base body (4) carrying the sensor element (2), with the following steps: - forming a sensor receptacle (3) for the sensor element (2) in the base body (4), - specifying at least one reference surface (7, 9; 11, 13) and / or at least one reference point (16, 17; 21) on the base body (4), - measuring a distance of the reference surface (7, 9; 11, 13) and / or the reference point (16, 17; 21) to a predetermined sensor location of the sensor element (2) in the sensor receptacle (3), - Mounting the sensor element (2) in the sensor holder (3), - Attaching the cover (5) to the sensor element (2), - Positioning the base body (4) relative to a support body (25) such that the at least one reference surface (7, 9; 11, 13) and / or the at least one reference point (16, 17; 21) has a predetermined position relative to the support body (25). [2] Method according to claim 1, characterized by that the sensor arrangement additionally includes: - a contact element (6) which is in electrical contact with the sensor element (2) on the one hand and with contact pins on the other hand, - wherein the contact element (6) is surrounded at least in sections by the base body (4), wherein - before the reference specification, the contact element (6) is surrounded by the base body (2) and wherein the sensor element (2) is contacted with the contact element (6) during mounting in the sensor holder (3). [3] Method according to claim 1 or 2, characterized by that at least two reference surfaces (7, 9; 11, 13) and / or reference points (16, 17) are specified. [4] Method according to one of claims 1 to 3, characterized by that at least one reference point (21) and at least one reference surface (13) are specified. [5] Method according to one of claims 1 to 4, characterized by that the base body (4) is formed by overmolding the contact element (6). [6] Method according to claim 5, characterized by that the sensor holder (3) is formed when the contact element (6) is overmolded. [7] Sensor arrangement with a sensor element (2) positioned according to one of claims 1 to 6. [8] Sensor arrangement according to claim 7, characterized by that the sensor element (2) is designed as a Hall sensor.

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